EMG 2504: CAD/CAM: Introduction To Computer Aided Manufacturing (CAM)

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Department of Mechanical Engineering
EMG 2504: CAD/CAM
Introduction to Computer Aided Manufacturing

(CAM)
James K. Kimotho
SoMMME
Computer Aided Manufacturing
CAM is the automation of machine tools by means of

computers executing pre-programmed sequences of machine
control commands.
This contrasts with machines that are manually controlled by
hand wheels or levers, or mechanically automated by cams
alone.
In modern CAM Systems:
– The part's geometry and dimensions are defined using CAD
software.
– Tool paths are translated into manufacturing directives
by computer aided manufacturing (CAM) software.
2 EMG 2504: Introduction to CAM/ 09.06.2022

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Computer Numerical Control (CNC) Machines
Computer numerical control (CNC) machines play an important

role in the manufacturing industry.
CNCs consist of a machine control unit (MCU) which performs
the following functions:
– turning the spindle on and off
– setting cutting speeds
– setting feed rate
– turning coolant on and off
– moving tool with respect to workpiece – machining

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Computer Numerical Control (CNC)

Advantages of CNC over conventional methods of machine control:
– higher precision:
• CNC machine tool are capable of machining at very close tolerances, in some
operations as small as 0.005 mm;
– machining of complex three-dimensional shapes;
– better quality:
• CNC systems can maintain constant working conditions for all parts in a batch thus
ensuring less spread of quality characteristics;
– higher productivity:
• CNC machine tools reduce drastically the non machining time. Adjusting the
machine tool for a different product:
– Changing the computer program
– Changing tool turret with the new set of cutting tools
– multi-operational machining:
• some NC machine tools, e.g., machine centers – perform a high number of
machining operations thus reducing the number of machine tools in the workshop.
– low operator qualification:

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Elements of CNC Machines
Input Devices
Part Programs
Machine Control Unit (MCU) Display

Unit
Data Processing Control Loop
Unit (DPU) Unit (CLU)
Feedback
Feedback
Position
Velocity
Motion Data Miscellaneous
Funtions
Driving Feedback
Machine Tool
System System

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Elements of CNC Machine
The main parts of the CNC machine are

Input Devices: These are the devices which are used to input
the part program in the CNC machine.
Machine Control Unit (MCU): It is the heart of the CNC
machine. It performs all the controlling action of the CNC
machine
Machine Tool: A CNC machine tool always has a slide table
and a spindle to control of the position and speed. The
machine table is controlled in X and Y axis direction and the
spindle is controlled in the Z axis direction.
Driving System: The driving system of a CNC machine
consists of amplifier circuits, drive motors and ball lead screws.

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Feedback System: This system consists of transducers that

acts as sensors.
– It contains position and speed transducers that continuously
monitor the position and speed of the cutting tool located at any
instant.
– The MCU receives the signals from these transducers, and it uses
the difference between the reference signals and feedback
signals to generate the control signals for correcting the position
and speed errors.
Display Unit: A monitor is used to display the programs,
commands and other useful data of CNC machine.

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The machine control unit (MCU) is further divided into two

elements:
1. Data Processing Unit (DPU)
– Processes the coded data that is read from input medium.
– It relays the CPU specific information such as the position of each
axis, its direction of motion feed and its auxiliary function control
signals.
2. Control-loop unit (CLU)
– Operates the drive mechanisms of the machine, receives
feedback signals about the actual position and velocity of the
axes, and communicates when operation has been completed

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CAM Hardware
3-axis coordinate
system

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Selection of CNC Systems
Classification of CNC systems

1) Number of axes
2) Control loops: open loop and closed loop
3) Power drives: hydraulic, electric, or pneumatic
4) Motion control: Point to point and continuous path
(contouring)
5) Positioning systems: incremental and absolute positioning

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Classification – Number of Axes
Linear motion
Rotary motion
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5-axis Horizontal milling machine

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5-axis Vertical Milling Machine

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3-axis wire Electrical discharge machining (EDM)

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3-axes Lathe machine

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3-axes CNC Laser cutting machine

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Classification – Motion Control
Point to Point (PTP)

– PTP motion control moves the machine table or spindle to a
specified position so that machining operations may be performed
at that point.
– The path taken to reach the specified point is not specified by the
programmer.

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Continuous (contouring) Control System

– The machine controls two or more axes simultaneously
– The machine controls the destination as well as the path through
which the tool reaches these positions.

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Contouring employs linear interpolation

– Control of the travel rate in two or more directions, which is
proportional to the distance moved
– If 𝑉𝑓 is the desired velocity along the line of motion, the velocities
along the two axes 𝑉𝑥 and 𝑉𝑦 , are:
– Where ∆𝑥 and ∆𝑦 are displacements along 𝑋 and 𝑌 axes

respectively

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Classification – Control Loop
There are two types of control loops:

a) Open-loop control
b) Closed-loop control

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The feedback control system consists of three independent

control loops for each axis of the machine tool;
– the outermost control loop is a position-control loop,
– the middle loop is a velocity-control loop, and
– the innermost loop is a current-control loop.
In general, the position-control loop is in the NC and the others
are in a servo driving device.

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Majority of NC systems use a closed loop control system due

to the high precision required in NC systems.
Most of these systems control servo-motors (either DC or AC).
A position transducer returns the current table position and
when the table reaches the programmed position, the motor
stops running.
The advantage of a closed-loop system is its positioning
accuracy.

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Control Loop
Open loop control can be found in some light-application NC

machines and in some point-to-point control applications.
Open-loop control NC systems normally use stepper motor
drives, where the stepper motor is controlled through a digital
signal.
Each pulse of the signal turns the motor a small fixed angle
(step angle). This movement is translated to the table to move
one basic length unit (BLU) – smallest programmable distance
of each axis.
No feedback to check how close the actual table movement
comes to the exact movement programmed.

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Classification – Power Drives
Power drives in CNCs:

– Servomotors
– Stepper motors
– Hydraulic drives
– Pneumatic drives
Most modern NCs use a DC or AC servomotor to drive the
table and spindle.
Some advantages of servo-motors are:
– they are small in size,
– easy to control,
– low cost.

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In some large machines, hydraulic drives are used. A hydraulic
motor has a larger power/size ratio.
For the same size as a DC motor, it can drive a much larger
load at a greater acceleration.
Disadvantages of hydraulic motors:
– increased noise
– difficult to maintain
– high power requirements
Pneumatic drives are normally used to drive auxiliary devices
attached to the machine, such as tool changer.
– They are rarely used for motion control due to the difficulty of
maintaining a precise continuous motion and position.
Rotational motors use a lead screw and a nut mechanism to
convert rotary motion into linear motion.

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CNC Machine Rating

A CNC machine is usually rated by the following factors:
– Accuracy XYZ 1510 VMC
Spindle 23 HP / 17 kW
– Repeatability
Table 1600 x 600 mm
– Spindle and axis-motor horsepower Axis Travel (XYZ) 1500 x 600 x 600mm
– No. of controlled axis Max Spindle Speed 10,000 RPM
Weight 9000 KG
– Dimensions of the workspace
Controller: Siemens Sinumeric 828D
– Features of the machine and the controller.
Accuracy measures how closely a CNC machine moves the tool
to the programmed position.
CNC machine accuracy results from a combination of the
control instrumentation, resolution and hardware accuracy.
The control resolution is the minimum length distinguishable by
the control unit. It is called the Basic Length Unit (BLU) and is
determined primarily by the axis transducer and lead screw that
are used.
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CNC Accuracy and Repeatability
Repeatability measures how closely a machine repeats a given

position command.
Repeatability is measured as the diameter of a circle enclosing
a target area produced by many repeated experiments.

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CNC Accuracy and Repeatability
Hardware inaccuracies are caused by physical machine errors

such as
– Inaccuracies in the machine elements
– Machine tool assembly errors
– Spindle run out
– Lead screw backlash
– Tool deflection
– Thermal errors

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Interpolation
Interpolation is the method by which contouring machine tools

move from one programmed point to the next.
The interpolator controls multiple axes simultaneously to move
the tool on a line, a circle, or a curve.
The ability to merge individual axis points into a predefined tool
path is built into most of todays MCUs.
There are five methods of interpolation: linear, circular, helical,
parabolic, and cubic.
All contouring controls provide linear interpolation, and most
controls are capable of both linear and circular interpolation.
Helical, parabolic, and cubic interpolation are used by
industries that manufacture parts which have complex shapes,
such as aerospace parts and dies for car bodies.

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Interpolation
Linear Interpolation
– Linear Interpolation consists of any programmed points linked
together by straight lines, whether the points are close together or
far apart.
– Curves can be produced with linear interpolation by breaking
them into short, straight-line segments.

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Interpolation
Circular Interpolation
– The development of MCUs capable of circular interpolation has
greatly simplified the process of programming arcs and circles.
– To program an arc, the MCU requires only the coordinate
positions (the XY axes) of the circle center, the radius of the circle,
the start point, and end point of the arc being cut, and the
direction in which the arc is to be cut (clockwise or
counterclockwise).
– The information required may vary with different MCUs.

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Interpolation
Helical Interpolation
– Combines circular and linear motion.
Parabolic and Cubic Interpolation

– Approximates free form curves using higher order equations

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Thank You
for
Your Kind Attention!
Dr.-Ing. James Kuria Kimotho Department of Mechanical Engineering
jkuria@eng.jkuat.ac.ke JKUAT
P.O. Box 62000-00200
Tel: +254791872389 Nairobi

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SoMMME

Department of Mechanical Engineering

EMG 2504: CAD/CAM

Introduction to Computer Aided Manufacturing

Computer Aided Manufacturing

CAM is the automation of machine tools by means of

2 EMG 2504: Introduction to CAM/ 09.06.2022

Computer Numerical Control (CNC) Machines

Computer numerical control (CNC) machines play an important

3 EMG 2504: Introduction to CAM/ 09.06.2022

Computer Numerical Control (CNC)

4 EMG 2504: Introduction to CAM/ 09.06.2022

Elements of CNC Machines

Machine Control Unit (MCU) Display

5 EMG 2504: Introduction to CAM/ 09.06.2022

Elements of CNC Machine

The main parts of the CNC machine are

6 EMG 2504: Introduction to CAM/ 09.06.2022

Elements of CNC Machine

Feedback System: This system consists of transducers that

7 EMG 2504: Introduction to CAM/ 09.06.2022

Elements of CNC Machine

The machine control unit (MCU) is further divided into two

8 EMG 2504: Introduction to CAM/ 09.06.2022

Elements of CNC Machine

9 EMG 2504: Introduction to CAM/ 09.06.2022

Selection of CNC Systems

Classification of CNC systems

10 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Number of Axes

Classification – Number of Axes

5-axis Horizontal milling machine

12 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Number of Axes

5-axis Vertical Milling Machine

13 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Number of Axes

14 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Number of Axes

3-axes Lathe machine

15 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Number of Axes

3-axes CNC Laser cutting machine

16 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Motion Control

Point to Point (PTP)

17 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Motion Control

Continuous (contouring) Control System

18 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Motion Control

Contouring employs linear interpolation

– Where ∆𝑥 and ∆𝑦 are displacements along 𝑋 and 𝑌 axes

19 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Control Loop

There are two types of control loops:

20 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Control Loop

The feedback control system consists of three independent

21 EMG 2504: Introduction to CAM/ 09.06.2022

Classification – Control Loop

Majority of NC systems use a closed loop control system due